Metal alloy and the process of forming the same



Patented May 20, 1930 PATENT OFFICE JENS J. OLSEN, OF SAN ANTONIO, TEXAS METAL ALLOY AND THE PROCESS OF FORMING THESAME No Drawing.

This invention relates to certain'in'iprovements in metal alloys; and the nature and objects of the invention will be readily recognized and understood by those skilled in the arts involved in the light of the following explanation and detailed description of one example or form of the alloy and of the alloy presenting variations in proportions, and ofthe process involving variations and changes in the steps thereof, of which the invention is capable within the spirit and scope thereof.

The invention is primarily directed to the production of a metal alloy for use in brazing and welding, although the alloy of the invention is not so limited as it possesses characteristics and qualities rendering it capable of other uses and applications. 'The metal forming the subject of the invention is an alloy of copper, iron, and nickel, and a general object of the invention is to form such an alloy which will possess among other characteristics, those particularly required of a brazing or welding metal, such as a proper melting point; flexibility; a sufficient degree of adhesion when applied tothe braze or weld; the required strength and toughness characteristics for such Work; and such an alloy which will not be prohibitive in cost.

Another general object of the invention is to provide a process or method by which a metal alloy having the above characteris tics can be formed or produced in an eflicient and relatively inexpensive manner, and through the medium of which the copper, iron, and nickel can be alloyed and the characteristics and qualities of the resulting alloy varied and controlled within limits.

Vith the foregoing general objects, and certain other objects and results in view which will be recognized by those skilled in the art from the following detailed examples, the invention consists in a new series or range of alloys from copper, iron and nickel having certain characteristics, and in'the novel steps of a method or process of forming or producing such alloys, as will be more fully and particularly referred to and specified hereinafter. 7

As .an example, one alloy within the inven- Application filed August 24, 1927. Serial No. 215,265.

tion comprises copper, iron and nickel in the relative proportions of 150 lbs. of copper; 5 lbs. of substantially pure iron and 2 lbs. of substantially pure nickel. This alloy in the approximate proportions by weight as above set forth, and when prepared in accordance with the process of the present invention as hereinafter described, possesses the several characteristics necessary for an eilicient brazing or welding metal, namely, strength and toughness with a sufficientlylow melting point, and the ability to adhere to the surface of'the metals being brazed or welded. \Vhen cast this metal alloy will test from 56,000 to 70,000 lbs. per square inch, and iron or steel brazed with this alloy'tests from 56,000 to 65,000 lbs. per square inch. The alloy can be cold rolled to any size down to wires and when cold rolled has tested to 110,000 lbs. per square inch. The alloy/with the lower percentages of nickel and iron has the property of flexibility or elasticity when hot while the alloy with higher percentages of nickel and iron cannot be efficiently forged when hot.

The hardness and flexibility of the alloy can be controlled by varying the proportion of copper, that is by increasing the proportion of copper a softer and more flexible alloy results, while a decrease in the proportion of copper produces'a harder and less flexible alloy. A practical range of copper, as based on the hereinbefore recited example, places the copper maximum at 150 lbs. for the soft and flexible alloy, and a minimum of 140 lbs. of copper for the hard alloy, although the invention is not neces sarily restricted to such range of copper proportions. With changes in the copper percentage corresponding changes in the iron and nickel percentages are made within a narrow range, the ratio of nickel and iron being about one-half, that is, two parts by weight of iron to one part by weight of nickel. As a further example, with 150 lbs. of copper the iron and nickel contents can vary through a range from approximately 1% lbs. of nickel and 3 lbs, of iron, to 3 lbs. of nickel to 7 lbs. of iron. The alloy is copper colored but lighter than pure copper, whil the-color of the alloy with the high ing ercentage of nickel and iron is about that of red brass.

In accordance with the process or method of theinvention, such an alloy thereof as in the example given above, is formed by melting, say 150 lbs. of copper in a crucible or furnace to a temperature of approximately 2,200 F. at which temperature 4 to 5 ounces of ferro-silicon embodying approximately 85% silicon, is added to the molten copper, although if desired pure silicon can be used. The addition of the silicon increases the solubility of the iron when added and results in a slight reduction of the melting point of the alloy. The metal is then cleaned and raised to a temperature of approximately 2,450 F. at which temperature 5 lbs. of substantially pure iron, and 2 lbs. of substantially pure nickel are added to the molten copper. The mixture is then stirred with preferably carbon stirring rods, although steel stirring rodscan be used.- Carbon is practically insoluble in the mixture, whereas with steel an excessive amount of the iron separates out, together with nickel, copper and silicon, which is taken up with it. Lowerof the iron percentage below the iron and nickel ratio of 2 :1, causes crystallization on cooling, and one of the functions of the iron in the alloy is to break down or prevent crystallization resulting from the silicon and nickel combination.

After the metals are well mixed from the stirring step, the mixture is covered with nickel sodium borate in order to produce a dense grain in the alloy and increase the adhesive qualities thereof for use as a brazing or welding metal. This double borate is formed by mixing powdered sodium borate.

with powdered nickel oxide in proportions by weight of 5 to 1 It is found that to A of a pound of the above double borate is sufficient to treat approximately 150 lbs. of the metal having approximately 8 to 10 inch diameter of surface exposure. Upon completion of the treatment with the catalytic agent or flux, which in this example is the double borate, the mixture is kept under a reduced atmosphere until poured when at a few degrees above its melting point.

The metal alloyas above formed by the method set forth, when used, for example, as a brazing or welding metal for iron or steel, is first heated, then dipped in a brazing flux or borax, and then is applied to the red hot surface of the iron or steel to be brazed, with the oxy-acetylene torch.

It will be evident that the alloys of the inveniton may vary in proportions, and that the steps of the process or method as well as the composition of the catalytic agents or fluxes used in the treatment of the alloys,

may be changed or varied, without departing,

from the spirit and scope of my invention,

and hence I do not desire to limit myself to v the exact and specific disclosures hereof.

The term iron is herein employed in a generic sense to include steel, and malleable, wrought, and cast irons, although certain rades of alloyed iron that contain other ob- Jectionable metals in excess of say slightly less than one and a half percent are harmful.

Pure silicon can be introduced into the al- 10y, or the silicon can be introduced as an alloy of any of the other ingredients, say as silicon-copper, silicon-nickel, ferro-silicon, or any combinations of the above.

Electrolytic copper and nickel are suitable for my purposes.

I have found boiler plate steel, and also transformer core iron, a soft silicon steel, very satisfactory as ingredients.

Desiring to protect my invention in the broadest manner legally possible, what I claim is:

1. An alloy containing copper, iron and nickel in approximately the proportions by weight of 140 to 150 lbs. of copper, 5 lbs. of iron, and 2 lbs. of nickel.

2. An alloy containing copper, iron and nickel in approximately the proportions by weight of 140110 150 lbs. of copper, 5 lbs. of iron, 2% lbs. of nickel, and 4 to 5 ozs. of ferrosilicon.

3. An alloy containing copper, iron and nickel in approximately the proportions by weight of 140 to 150 lbs. of copper, 5 lbs. of iron, 2 lbs. of nickel, and 4; to 5 ozs. of ferrosilicon having an 85% silicon content.

4. An alloy containing copper, iron, and nickel, in approximately the proportions by Weight of 140 to 150 lbs. of copper; 1% to 3 lbs. of nickel; and 3 to 7 lbs. of iron.

5. An alloy containing copper, iron and nickel in approximately the proportions by weight of 140 to 150 lbs. of copper; 1% to 3% lbs. of nickel; 3% to 7 lbs. of iron; and not exceeding approximately 5 ozs. of silicon.

I Signed at San Antonio, Texas, this 16th day of August, 1927.

" JENS J. OLSEN. 

